In the global new energy vehicle (NEV) industry, including pure electric vehicles, plug-in hybrid vehicles and fuel cell vehicles, the safety, stability and durability of vehicle-mounted components are crucial to driving safety and user experience. New energy vehicles operate in complex and harsh environments such as frequent vibration, extreme temperature fluctuations, rain erosion, road dust and potential fire risks, putting forward strict requirements for the sealing, cushioning, flame retardancy and weather resistance of internal and external components. New energy vehicle silicone foam is a professional functional material specially developed for NEV scenarios, tailored to the unique operating characteristics of vehicle-mounted equipment. Tengye supplies high-performance new energy vehicle silicone foam, fabricated with automotive-grade silicone raw materials and precision closed-cell foaming technology, to provide all-round, reliable protection for various NEV components and ensure the safe and stable operation of the whole vehicle.
Automotive-Grade Silicone Material & NEV-Optimized Foaming Process
Our new energy vehicle silicone foam adopts imported high-purity, automotive-grade silicone raw materials, with a halogen-free, low-smoke, non-toxic and environment-friendly formula that is specially optimized for the harsh vehicle-mounted environment. We adopt advanced closed-cell foaming technology to form a uniform and dense porous internal structure, which perfectly balances soft flexibility, high resilience, wear resistance and long-lasting sealing performance, eliminating material defects that may cause abrasion, corrosion or damage to NEV batteries, electronic modules and structural components.
This professional automotive-grade silicone foam features an ultra-wide operating temperature range from -60℃ to 230℃, maintaining stable physical properties even under extreme working conditions such as high-temperature operation of vehicle-mounted batteries, low-temperature cold start and long-term exposure to sunlight, without hardening, cracking, softening or deformation. It has outstanding vibration resistance and fatigue resistance, effectively withstanding frequent mechanical vibration during vehicle driving, and also boasts excellent chemical resistance to prevent damage from automotive oils, battery electrolyte, cleaning agents and road corrosive substances. All products fully comply with RoHS 2.0, REACH, UL 94 V-0 and automotive industry standards (such as IATF 16949), with authoritative third-party test reports from SGS, Intertek and other institutions available for verification, fully meeting the strict safety and quality requirements of the global new energy vehicle industry.
Core Performance Advantages for New Energy Vehicles
Targeted at the unique pain points of new energy vehicle operation, our new energy vehicle silicone foam breaks through the limitations of traditional foam and sealing materials, with fully optimized performance to meet the high-standard protection needs of NEV components, covering all-round functional advantages:
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Excellent Vibration Absorption & Fatigue Resistance: The unique porous foamed structure efficiently absorbs and buffers frequent vibration and impact generated during vehicle driving, acceleration, braking and rough road driving, reducing stress on vehicle-mounted batteries, electronic modules, wiring harnesses and structural components, preventing loose connections, component damage and noise generation, ensuring long-term stable operation.
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Top-Tier Flame Retardancy: Meets UL 94 V-0 the highest flame retardant standard, self-extinguishing immediately after leaving the fire, with no molten dripping and no release of toxic and harmful gases, effectively blocking the spread of fire, eliminating potential fire risks of vehicle-mounted battery packs, electronic control systems and engine compartments (for hybrid vehicles).
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High-Level Waterproof & Dustproof: The dense closed-cell structure achieves IP67-IP68 professional protection rating, effectively blocking rainwater, moisture, road dust, sediment and fine particles from invading vehicle-mounted components, avoiding circuit short circuits, battery corrosion, poor contact of electronic modules and performance attenuation caused by water and dust intrusion, adapting to complex outdoor driving environments.
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Superior High/Low Temperature Resistance: Specially optimized for vehicle-mounted temperature changes, it maintains stable flexibility and resilience in extreme high-temperature (engine compartment, battery pack heating) and low-temperature (cold area start) environments, without performance degradation, ensuring reliable protection in all climate conditions.
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Low Compression Set & Durable Resilience: Possesses exceptional rebound performance, with a compression set of ≤5% after long-term continuous compression, retaining tight fitting and sealing effect under sustained assembly pressure, avoiding sealing failure caused by permanent deformation during long-term vehicle operation.
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Vehicle-Friendly & Non-Corrosive: The material is neutral and non-corrosive, with no chemical reaction with NEV battery shells, metal structural parts, plastic components and electronic circuits, ensuring no damage to vehicle components during long-term contact use, and compatible with various automotive materials.
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Lightweight & Easy Installation: Light in weight, soft in texture and good in fit, it can closely attach to irregular gaps, flanges and curved surfaces of vehicle-mounted components, compatible with automotive automated assembly lines and manual installation, effectively improving production efficiency and assembly accuracy.
Main Application Scenarios
Our new energy vehicle silicone foam is widely used in various components of new energy vehicles with high safety, vibration resistance and protection requirements, covering all core parts of NEVs:
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Vehicle-Mounted Battery Pack: Sealing, cushioning and flame-retardant protection for power battery pack shells, module gaps, wiring harness ports and upper/lower cover flanges, adapting to the harsh working environment of battery packs.
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Electronic Control System: Sealing and shock absorption for vehicle control unit (VCU), battery management system (BMS), motor controller and other electronic modules, ensuring stable operation of the control system.
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Vehicle Body & Cabin: Sealing for door gaps, window frames, dashboard, central control screen and air conditioning vents, providing sound insulation, dustproof and waterproof effects, improving driving comfort.
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Engine Compartment (Hybrid NEVs): Sealing and heat insulation for engine compartment components, wiring harnesses and sensor interfaces, resisting high temperature and oil erosion.
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Charging System: Sealing protection for on-board chargers, charging ports and charging cables, preventing water and dust intrusion and ensuring charging safety.
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Chassis & Structural Components: Cushioning and shock absorption for chassis components, suspension system and wiring harness fixing, reducing vibration and noise, protecting components from damage.
Custom OEM/ODM Service
We provide comprehensive personalized customization solutions to match the diversified structures, sizes and performance needs of different new energy vehicle models and components, supporting personalized R&D testing, small-batch trial production and large-scale mass production:
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Specification & Shape Customization: Customize thickness (1mm-20mm), density, hardness, color and external dimensions according to customer needs; support die-cutting, molding and special-shaped processing based on 2D/3D drawings or physical samples of NEV components.
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Performance Optimization: Adjust material formulas to enhance vibration resistance, flame retardancy, high/low temperature resistance and waterproofing; optional self-adhesive backing, wear-resistant treatment and anti-static processing to meet the assembly needs of NEV components.
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Rapid Prototyping: Deliver customized samples within 7-12 days for NEV component fitment and performance testing, with timely adjustments according to customer feedback to meet actual vehicle installation and production requirements.
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Stable Mass Production: Support small-batch trial production for NEV R&D and large-scale continuous production for vehicle mass production, with complete quality traceability system to ensure consistent product quality and on-time supply, complying with automotive industry production standards.
Precautions for Use
To ensure the full performance of new energy vehicle silicone foam, extend its service life and guarantee stable protection effect during long-term vehicle operation, please strictly abide by the following guidelines during installation, use and storage:
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Before installation, thoroughly clean the bonding surface of NEV components (battery packs, electronic modules, vehicle body parts) to keep it dry, smooth, free of oil, dust, burrs and impurities, ensuring a tight and gap-free fit between the foam and the component surface.
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Control the compression ratio reasonably during installation, generally controlled at 30%-50%, avoid excessive compression to prevent permanent deformation of the foam, which will directly affect its vibration absorption, sealing, flame retardancy and temperature resistance performance.
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Store the product in a cool, dry and ventilated environment before installation, avoid long-term exposure to strong sunlight, high-temperature heat sources and open flames, and keep away from flammable, explosive and corrosive chemicals (such as automotive oil, battery electrolyte) to prevent premature aging and performance degradation.
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Select the appropriate product specifications, thickness, hardness and performance grade according to the actual application position (battery pack/electronic control/vehicle body), vehicle model and automotive industry safety standard requirements.
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During transportation, handling and installation, avoid sharp object scratches, heavy pressure and violent impact on the foam, so as not to damage the internal foaming structure and external shape, affecting its normal protection performance.
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During vehicle maintenance, check the fitting condition of the foam regularly, especially for components in harsh environments (battery pack, chassis), and replace the aged, deformed or damaged foam in a timely manner to maintain the protection effect of NEV components.
Strict Quality Control System
Adhering to the principle of "quality first, safety supreme", we implement a full-process strict quality control system for new energy vehicle silicone foam, covering raw material procurement, production processing to finished product delivery, complying with IATF 16949 automotive quality management system, ensuring each batch of products meets the high standards of the new energy vehicle industry:
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Raw Material Inspection: 100% full inspection of automotive-grade silicone raw materials, verifying vibration resistance, flame retardancy, high/low temperature resistance, environmental protection indicators and vehicle component compatibility before entering the production process.
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In-Process Monitoring: Real-time dynamic control of foaming, molding and cutting parameters to ensure uniform pore structure, accurate dimensional tolerance and no defects such as bubbles, burrs, cracks and flash, meeting automotive assembly accuracy requirements.
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Finished Product Testing: Conduct comprehensive performance tests including vibration absorption, flame retardancy, waterproofing, high/low temperature cycle and compression set, issuing complete test reports and certification documents for each batch, ensuring product consistency and reliability.
Tengye: Your Trusted NEV Sealing Partner
At Tengye, we focus on the R&D, production and customized services of high-performance new energy vehicle silicone foam, relying on professional foaming technology, strict quality control and intimate after-sales support, to provide safe, durable and reliable sealing and cushioning solutions for global new energy vehicle manufacturers and component suppliers. We are committed to improving the safety, stability and service life of new energy vehicles, and becoming a long-term trusted core partner in the global new energy vehicle industry. Contact us today to get a free technical consultation, customized sample and exclusive quotation for vehicle mass production!
